EP0369134A1 - Vehicle body - Google Patents

Vehicle body Download PDF

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Publication number
EP0369134A1
EP0369134A1 EP89117089A EP89117089A EP0369134A1 EP 0369134 A1 EP0369134 A1 EP 0369134A1 EP 89117089 A EP89117089 A EP 89117089A EP 89117089 A EP89117089 A EP 89117089A EP 0369134 A1 EP0369134 A1 EP 0369134A1
Authority
EP
European Patent Office
Prior art keywords
vehicle
parts
cell according
cell modules
vehicle cell
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP89117089A
Other languages
German (de)
French (fr)
Other versions
EP0369134B1 (en
Inventor
Peter-Martin Wackerle
Franz Sperber
Josef Gröber
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
AEG Schienenfahrzeuge Nahverkehr und Wagen GmbH
Original Assignee
Messerschmitt Bolkow Blohm AG
MAN GHH Schienenverkehrstechnik GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Messerschmitt Bolkow Blohm AG, MAN GHH Schienenverkehrstechnik GmbH filed Critical Messerschmitt Bolkow Blohm AG
Priority to AT89117089T priority Critical patent/ATE90631T1/en
Publication of EP0369134A1 publication Critical patent/EP0369134A1/en
Application granted granted Critical
Publication of EP0369134B1 publication Critical patent/EP0369134B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D17/00—Construction details of vehicle bodies
    • B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D17/00—Construction details of vehicle bodies
    • B61D17/04—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures
    • B61D17/043—Construction details of vehicle bodies with bodies of metal; with composite, e.g. metal and wood body structures connections between superstructure sub-units
    • B61D17/045—The sub-units being construction modules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D17/00—Construction details of vehicle bodies

Definitions

  • the invention relates to a vehicle cell, in particular for a rail vehicle, according to the preamble of claim 1.
  • the complete supporting structure is first set up - usually by welding the individual scaffolding parts including the window and door frames - and then the sandwich parts forming the outer skin and possibly an additional inner lining are attached to the finished cell.
  • Such a design has a disadvantageous impact on the manufacturing costs, as on the one hand complex manufacturing resources for the construction of the raw cell, for. B. an expensive assembly rig, must be provided and on the other hand, the subsequent planking of the supporting structure with the outer and inner cladding parts is a labor-intensive and accordingly cost-intensive process.
  • the object of the invention is to design a vehicle cell of the type mentioned at the outset in such a way that it can be produced using simple manufacturing means and with little effort.
  • the supporting framework parts are already integrated as integral components in the respective sandwich structures before the cell is assembled and fit there, including those arranged on the framework parts exact connection elements exactly and securely fixed in the final assembly position between the cover layers, so that the inner supporting structure and the sandwich paneling of the cell no longer have to be assembled in separate, complex production steps and with the help of a large-scale assembly rig; Rather, the cell modules according to the invention, if desired already provided with the inner cladding, can be made separately from the final installation location in an extremely rational manner by means of simple, flat or, if necessary, simply curved molding and adhesive devices, and then can be assembled quickly and easily by assembling their connecting elements into the finished vehicle cell, what brings a very significant reduction in the cost of production resources and labor.
  • a preferred embodiment of the invention with regard to a problem-free joining of the individual cell modules consists in that the fitting connections consist of plug-in connection elements which, after being plugged together, are coupled to each other in a load-transmitting manner, and that are preferably glued together according to claim 3.
  • the individual cell modules are expediently completely surrounded at the edges by supporting frame parts provided with fitting connections, which results in a very uniform and therefore highly load-resistant coupling of the supporting frame in the area of the fitting connections over the entire outer edge of the cell modules and at the same time in a simple manner a clean edge seal for the individual sandwich structures is achieved.
  • the supporting frame parts are preferably designed as hollow profile parts which can be pushed into one another in the edge region of the cell modules.
  • the support structure parts within the individual cell modules are preferably connected to one another in a grid-like manner, expediently according to claim 7 by assembly simple expansion dowel screw connections.
  • a further, manufacturing simplification is achieved according to claim 8 in that the support layer sections are inserted via a leveling adhesive between the framework parts of the respective cell module, so that an exact cut of these support layer sections can be dispensed with in cell module production, the support layer sections preferably consisting of a honeycomb core or Foam material exist that adapts very easily to the required curvature course in the production of curved cell modules and without great effort to change the shape.
  • the frame profiles for the vehicle windows and doors are integrated into the respective cell modules in the same way as the supporting frame parts, as a result of which the assembly effort in the area of the window and door cutouts is also substantially reduced, and in With a view to further simplifying production, the cover layers are expediently only after the completion of the respective cell modules along the window or door Trimmed frame profiles, so that a previous, tailored cut of the cover skins on the window and door cutouts of the cell is not required.
  • the cover layers preferably consist of fiber composite layers, which are glued flat to the supporting frame parts and, if the adhesive connection is to be strengthened locally, are also additionally riveted in places according to claim 12.
  • a pre-hardened fiber composite laminate is used in the manufacture of the cell modules at least as the outer skin, whereby impressions of the supporting structure and other sandwich inserts, eg. B. of honeycomb core cuts, on the outside or inside of the cell modules can be effectively prevented and thus the vehicle receives a smooth surface outside and inside without it having to undergo expensive surface finishing, eg. B. by grinding, or a retrofitted, additional inner lining is required.
  • the rail vehicle cell shown in Fig. 1 consists of individually prefabricated roof, floor, end (not shown) and side wall cell modules 2.1 to 2.4, which, in the assembled state, the supporting structure of the vehicle cell, which is composed of individual supporting profile parts, and the sandwich which takes over the shear stiffening - Planking of the supporting structure results.
  • the construction and manufacture of the cell modules is explained using a side wall submodule with reference to FIG. 2.
  • the cell module is designed as a sandwich structure with inner and outer cover layers 4, 6 made of fiber composite material, between which a honeycomb core support layer 8 and the supporting profile parts 10 of the supporting structure belonging to the cell module are glued as an integral part of the sandwich structure.
  • the support profile parts 10 are arranged in a lattice-like manner such that the outer transverse and longitudinal profiles 12, 14 form a circumferential border for the sandwich structure.
  • a molded shell 16 made of aluminum or steel sheet is used to produce the side wall cell module
  • Layer is raised and on which the two cover layers 4, 6 are first individually manufactured and cured with a predominantly ⁇ 45 ° fiber layer structure. After hardening, the outer surfaces of the cover layers 4, 6 on the shell side have a very smooth surface structure, so that a complicated surface reworking or a subsequent application to the outer surface of the inner cover layer 4 is carried out
  • Vehicle interior trim can be dispensed with.
  • the outer cover layer 6 lying on the molded shell 16 is covered with an adhesive layer, for example a phenolic resin layer or a film adhesive (not shown), whereupon the support profile parts 10 are placed and inserted into the interspaces between them, any insert parts that may still be required, e.g. B. force introduction elements in the form of glass chips blocks (also not shown) can be used.
  • the remaining surface areas, with the exception of the surface fields to be kept free for the window and door cutouts, are now covered with the honeycomb core material 8.
  • the support profile parts 10 are prefabricated as hollow chamber profiles made of aluminum or fiber composite material and, with regard to an exact positioning within the cell module, are already included in FIG the sandwich structure firmly connected to each other, preferably by expansion dowel connections 20 according to FIG. 3, each screwed from a dowel part 22 inserted into the open end of the one support profile part 10 and screwed to it with the dowel part 22 spreading, via through holes in the hollow chamber walls of the other support profile part 14 are inserted mounting screws 24.
  • the molded shell 16 is also used for the production of cell modules which, like the roof modules 2.1, have a cross-sectional configuration that is curved on one side.
  • the individual cell modules are assembled using precisely fitting plug connections that extend over a large area over the entire outer circumference of the cell modules.
  • the edge-side support profile parts 12 and 14 are glued to the cover layers 4, 6 only over part of their profile width and are coupled via their cover layer-free profile sections to the edge-side support profile part 12 and 14 of the adjacent cell module in a load-transmitting manner.
  • 4 shows a pass-fit connection of this type between the base and side wall modules 2.2 and 2.4.
  • the double-chamber support profile parts 14, which form the outer border of the cell module adjoining the honeycomb core 8 with the interposition of the compensating adhesive or foam 26, are approximately only half of their profile width in the Sanwich structure pulled and are firmly connected to each other with the help of a connector profile 28, which is pushed onto the cover layer-free hollow chamber profile sections and glued to them, the free profile legs of the connection profile 28 in the assembled state flush with the cover layers 4, 6 of the cell modules 2.2 or 2.4 concern.
  • a hollow profile 30 that is open on one side is provided as the edge-side supporting profile part of the roof module 2.1, the free profile legs 32 of which, when the cell modules 2.1, 2.3 are assembled, fit snugly onto the edge-side counter profile 14 of the Sidewall module 2.3 can be pushed on, so that the edge profiles 14, 30 can in turn be glued to one another with exact mutual fixation of the associated cell modules 2.1 and 2.3.
  • the joint connections described consisting of edge profile parts 12, 14, 30 which can be pushed together precisely in the lateral direction and then bonded to one another, are also used in an analogous manner between the other cell modules, for example between the roof and end wall modules or for inserting intermediate wall modules 2.4 (FIG. 1) .
  • the supporting structure parts 10 with the cover layers 4, 6 or - at the fitting connections between the cell modules - can also be riveted or screwed to one another.
  • Fig. 5 also shows the possibility of forming the cell module with a different wall thickness compared to the profile height of the edge-side support profile parts, such that by inserting appropriate honeycomb core strips 8.2 in cell module production a gradual transition from the sandwich thickness to the profile height of the edge-side support profile part 14 is achieved.
  • the window and door frame profiles 34 and 36 are also integrated into the sandwich structure 2, as shown in FIGS. 6a, b. Visible radii at the corners of the window or door cutouts are already formed on the frame profiles 34, 36, and excess cover layer material is removed after trimming the sandwich structure 2 by trimming along the frame profile edges.
  • the window panes 38 are subsequently attached to the frame profiles 34 together with a rubber seal 40 and a rim 42.
  • the door frame profile 36 contains an integrally molded profile section 44 forming the door stop (FIG. 6b); Alternatively, however, the door frame profile 36 can also be formed in two parts - along the dividing line dashed in FIG. 6b - and the profile section 44 can be fastened to the door frame profile 36 only after the side wall module 2.3 has been completed.
  • the outer layers 4, 6 are not cured beforehand, and instead they are placed in the still uncured state together with the honeycomb core and supporting frame parts 8, 10 on the molding tool 16, 18 and then with simultaneous bonding of the Hardened sandwich structure.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Body Structure For Vehicles (AREA)
  • Laminated Bodies (AREA)
  • Preparation Of Compounds By Using Micro-Organisms (AREA)
  • Arrangement Or Mounting Of Propulsion Units For Vehicles (AREA)

Abstract

Eine Schienenfahrzeugzelle, die aus einem Traggerüst und an diesem befestigten Sandwichteilen mit einer äußeren und einer inneren Deckschicht (4, 6) und einer zwischen diese eingeklebten Stützschicht (8) besteht, ist erfindungsgemäß im Hinblick auf eine kostengünstige Fertigung und vor allem eine Verringerung des Montageaufwandes aus einzeln fertiggestellten Zellmodulen aufgebaut, die jeweils in Integralbauweise als Sandwichstruktur mit im Bereich der Stützschicht eingefügten, an den Deckschichten befestigten Traggerüstteilen (10) ausgebildet und randseitig an den Traggerüstteilen mit Passverbindungen (12, 14) zum Zusammenfügen der Zellmodule versehen sind.A rail vehicle cell, which consists of a supporting frame and sandwich parts fastened to it with an outer and an inner cover layer (4, 6) and a support layer (8) glued between them, is in accordance with the invention with regard to cost-effective production and, above all, a reduction in assembly effort made up of individually finished cell modules, each of which is constructed in an integral construction as a sandwich structure with support frame parts (10) inserted in the area of the support layer and attached to the cover layers and provided with fitting connections (12, 14) on the edge of the support frame parts for joining the cell modules.

Description

Die Erfindung bezieht sich auf eine Fahrzeugzelle, insbe­sondere für ein Schienenfahrzeug, nach dem Oberbegriff des Anspruchs 1.The invention relates to a vehicle cell, in particular for a rail vehicle, according to the preamble of claim 1.

Bei der Herstellung derartiger Fahrzeugzellen bekannter Bauart wird zunächst das komplette Traggerüst - zumeist durch Verschweißen der einzelnen Gerüstteile einschließ­lich der Fenster- und Türrahmen - aufgebaut und an der so fertiggestellten Rohzelle werden anschließend die die Außenhaut bildenden Sandwichteile und eventuell noch eine zusätzliche Innenverkleidung angebracht. Eine derar­tige Bauweise hat insofern nachteilige Auswirkungen auf die Herstellungskosten, als zum einen für den Aufbau der Rohzelle aufwendige Fertigungsmittel, z. B. ein kost­spieliges Montagerig, bereitgestellt werden müssen und zum anderen die nachträgliche Beplankung des Trag­gerüstes mit den äußeren und inneren Verkleidungsteilen ein arbeits- und dementsprechend kostenintensiver Vor­gang ist.In the manufacture of such vehicle cells of a known type, the complete supporting structure is first set up - usually by welding the individual scaffolding parts including the window and door frames - and then the sandwich parts forming the outer skin and possibly an additional inner lining are attached to the finished cell. Such a design has a disadvantageous impact on the manufacturing costs, as on the one hand complex manufacturing resources for the construction of the raw cell, for. B. an expensive assembly rig, must be provided and on the other hand, the subsequent planking of the supporting structure with the outer and inner cladding parts is a labor-intensive and accordingly cost-intensive process.

Aufgabe der Erfindung ist es, eine Fahrzeugzelle der eingangs genannten Art so auszubilden, daß sie mit ein­fachen Fertigungsmitteln und einem geringen Arbeitsauf­wand herstellbar ist.The object of the invention is to design a vehicle cell of the type mentioned at the outset in such a way that it can be produced using simple manufacturing means and with little effort.

Diese Aufgabe wird erfindungsgemäß durch die im Anspruch 1 gekennzeichnete Fahrzeugzelle gelöst.This object is achieved by the vehicle cell characterized in claim 1.

Erfindungsgemäß sind die Traggerüstteile bereits vor dem Zusammenbau der Zelle als integrale Bestandteile in die jeweiligen Sandwichstrukturen einbezogen und dort ein­schließlich der an den Gerüstteilen angeordneten, pass­ genauen Anschlußelemente exakt und sicher in der end­gültigen Montageposition zwischen den Deckschichten fixiert, so daß das innere Traggerüst und die Sandwich-­Beplankung der Zelle nicht mehr in voneinander getrenn­ten, jeweils aufwendigen Fertigungsschritten und unter Zuhilfenahme eines großräumigen Montagerigs montiert werden müssen; vielmehr lassen sich die erfindungsspezi­fischen, gewünschtenfalls auch bereits mit der Innen­verkleidung versehenen Zellmodule getrennt vom endgülti­gen Montageort auf äußerst rationelle Weise mittels ein­facher, ebener oder allenfalls einfach gekrümmter Form- und Klebevorrichtungen anfertigen und dann durch Zusam­menfüger ihrer Anschlußelemente rasch und problemlos zur fertigen Fahrzeugzelle zusammenbauen, was eine ganz erhebliche Reduzierung des Fertigungsmittel- und Arbeits­aufwands erbringt.According to the invention, the supporting framework parts are already integrated as integral components in the respective sandwich structures before the cell is assembled and fit there, including those arranged on the framework parts exact connection elements exactly and securely fixed in the final assembly position between the cover layers, so that the inner supporting structure and the sandwich paneling of the cell no longer have to be assembled in separate, complex production steps and with the help of a large-scale assembly rig; Rather, the cell modules according to the invention, if desired already provided with the inner cladding, can be made separately from the final installation location in an extremely rational manner by means of simple, flat or, if necessary, simply curved molding and adhesive devices, and then can be assembled quickly and easily by assembling their connecting elements into the finished vehicle cell, what brings a very significant reduction in the cost of production resources and labor.

Eine im Hinblick auf ein problemloses Zusammenfügen der einzelnen Zellmodule bevorzugte Ausgestaltung der Erfin­dung besteht gemäß Anspruch 2 darin, daß die Passver­bindungen aus Steckverbindungselementen bestehen, die nach dem Zusammenstecken lastübertragend miteinander ver­koppelt, und zwar gemäß Anspruch 3 vorzugsweise miteinan­der verklebt werden.A preferred embodiment of the invention with regard to a problem-free joining of the individual cell modules consists in that the fitting connections consist of plug-in connection elements which, after being plugged together, are coupled to each other in a load-transmitting manner, and that are preferably glued together according to claim 3.

Die einzelnen Zellmodule sind gemäß Anspruch 4 zweckmäßi­gerweise randseitig jeweils vollständig von mit Passver­bindungen versehenen Traggerüstteilen umschlossen, wo­durch sich eine über den gesamten Außenrand der Zellmo­dule sehr gleichmäßige und daher hochgradig lastfeste Verkoppelung des Traggerüstes im Bereich der Passver­bindungen ergibt und zugleich auf einfache Weise ein sauberer Randabschluß für die einzelnen Sandwichstruktu­ren erzielt wird.The individual cell modules are expediently completely surrounded at the edges by supporting frame parts provided with fitting connections, which results in a very uniform and therefore highly load-resistant coupling of the supporting frame in the area of the fitting connections over the entire outer edge of the cell modules and at the same time in a simple manner a clean edge seal for the individual sandwich structures is achieved.

Im Hinblick auf eine konstruktiv besonders einfache Aus­bildung der Pass- bzw. Steckverbindungen bei zugleich geringem Eigengewicht der Traggerüstkonstruktion sind die Traggerüstteile gemäß Anspruch 5 vorzugsweise als im Randbereich der Zellmodule passgenau ineinander schieb­bare Hohlprofilteile ausgebildet.With regard to a particularly simple design of the fitting or plug connections at the same time Low weight of the supporting structure construction, the supporting frame parts are preferably designed as hollow profile parts which can be pushed into one another in the edge region of the cell modules.

Aus Gründen einer erhöhten konstruktiven Festigkeit und vor allem auch um bei der Fertigung der einzelnen Zell­module die exakte gegenseitige Positionierung der jewei­ligen Traggerüstteile zu erleichtern, sind die Traggerüst­teile innerhalb der einzelnen Zellmodule gemäß Anspruch 6 vorzugsweise gitterartig miteinander verbunden, und zwar zweckmäßigerweise gemäß Anspruch 7 durch montage­mäßig einfache Spreizdübel-Verschraubungen.For reasons of increased structural strength and, above all, to facilitate the exact mutual positioning of the respective support structure parts during the manufacture of the individual cell modules, the support structure parts within the individual cell modules are preferably connected to one another in a grid-like manner, expediently according to claim 7 by assembly simple expansion dowel screw connections.

Eine weitere, ferigungsmäßige Vereinfachung wird gemäß Anspruch 8 dadurch erreicht, daß die Stützschichtab­schnitte über einen Ausgleichskleber zwischen die Ge­rüstteile des jeweiligen Zellmoduls eingefügt sind, so daß auf einen exakten Zuschnitt dieser Stützschichtab­schnitte bei der Zellmodulfertigung verzichtet werden kann, wobei die Stützschichtabschnitte vorzugsweise aus einem Wabenkern oder Schaumstoffmaterial bestehen, das sich bei der Herstellung gekrümmter Zellmodule sehr einfach und ohne großen Formänderungsaufwand elastisch an den geforderten Krümmungsverlauf anpaßt.A further, manufacturing simplification is achieved according to claim 8 in that the support layer sections are inserted via a leveling adhesive between the framework parts of the respective cell module, so that an exact cut of these support layer sections can be dispensed with in cell module production, the support layer sections preferably consisting of a honeycomb core or Foam material exist that adapts very easily to the required curvature course in the production of curved cell modules and without great effort to change the shape.

Gemäß einem weiteren, besonders bevorzugten Aspekt der Erfindung sind nach Anspruch 9 die Rahmenprofile für die Fahrzeugfenster und -türen in gleicher Weise wie die Traggerüstteile in die jeweiligen Zellmodule mitintegriert, wodurch der Montageaufwand im Bereich der Fenster- und Türausschnitte ebenfalls wesentlich verrin­gert wird, und im Hinblick auf eine weitere, fertigungs­mäßige Erleichterung werden die Deckschichten gemäß An­spruch 10 zweckmäßigerweise erst nach Fertigstellung der jeweiligen Zellmodule längs der Fenster- bzw. Tür­ rahmenprofile besäumt, so daß ein vorheriger, passgenauer Zuschnitt der Deckhäute an den Fenster- und Türausschnit­ten der Zelle nicht erforderlich ist.According to a further, particularly preferred aspect of the invention, the frame profiles for the vehicle windows and doors are integrated into the respective cell modules in the same way as the supporting frame parts, as a result of which the assembly effort in the area of the window and door cutouts is also substantially reduced, and in With a view to further simplifying production, the cover layers are expediently only after the completion of the respective cell modules along the window or door Trimmed frame profiles, so that a previous, tailored cut of the cover skins on the window and door cutouts of the cell is not required.

Gemäß Anspruch 11 bestehen die Deckschichten vorzugswei­se aus Faserverbundschichten, die mit den Traggerüst­teilen flächig verklebt und, falls die Klebeverbindung örtlich noch verstärkt werden soll, gemäß Anspruch 12 zweckmäßigerweise zusätzlich auch noch stellenweise ver­nietet sind.According to claim 11, the cover layers preferably consist of fiber composite layers, which are glued flat to the supporting frame parts and, if the adhesive connection is to be strengthened locally, are also additionally riveted in places according to claim 12.

Gemäß Anspruch 13 schließlich wird bei der Fertigung der Zellmodule zumindest als Deckschicht-Außenhaut ein vor­gehärtetes Faserverbundlaminat verwendet, wodurch Ab­drücke der Traggerüst- und anderer Sandwich-Einlegeteile, z. B. von Wabenkernzuschnitten, auf der Außen- bzw. Innen­seite der Zellmodule wirksam verhindert werden und somit das Fahrzeug außen wie innen eine glatte Oberfläche er­hält, ohne daß es einer aufwendigen Oberflächen-Nachbear­beitung, z. B. durch Schleifen, oder einer nachträglich montierten, zusätzlichen Innenverkleidung bedarf.Finally, according to claim 13, a pre-hardened fiber composite laminate is used in the manufacture of the cell modules at least as the outer skin, whereby impressions of the supporting structure and other sandwich inserts, eg. B. of honeycomb core cuts, on the outside or inside of the cell modules can be effectively prevented and thus the vehicle receives a smooth surface outside and inside without it having to undergo expensive surface finishing, eg. B. by grinding, or a retrofitted, additional inner lining is required.

Die Erfindung wird nunmehr anhand des in Figuren schema­tisch dargestellten Ausführungsbeispieles näher erläu­tert. Es zeigen:

  • Fig. 1 eine perspektivische Teildarstellung einer Fahrzeugzelle nach der Erfindung;
  • Fig. 2 die Einzelkomponenten eines der Zellmodule in perspektivischer Ansicht;
  • Fig. 3 einen Schnitt einer Schraub-Spreizverbindung zwischen zwei Traggerüstteilen innerhalb eines Zellmoduls längs der Linie III-III der Fig. 2;
  • Fig. 4 einen Schnitt einer Pass-Steckverbindung zwischen zwei Zellmodulen im Eckbereich IV der Fig. 1 vor dem Zusammenfügen;
  • Fig. 5 einen Schnitt einer Pass-Steckverbindung im Seitenwand-Dachbereich V der Fig. 1 vor dem Zusammenfügen;
  • Fig. 6 a, b eine perspektivische bzw. geschnittene Teilansicht des Fenster- bzw. Türrahmen­bereichs längs der Linie VI-VI der Fig. 1.
The invention will now be explained in more detail with reference to the exemplary embodiment shown schematically in the figures. Show it:
  • Figure 1 is a partial perspective view of a vehicle cell according to the invention.
  • 2 shows the individual components of one of the cell modules in a perspective view;
  • 3 shows a section of a screw-expansion connection between two supporting frame parts within a cell module along the line III-III of FIG. 2;
  • 4 shows a section of a fitting plug connection between two cell modules in the corner region IV of FIG. 1 before assembly;
  • 5 shows a section of a fitting plug connection in the side wall roof area V of FIG. 1 before assembly;
  • 6 a, b is a perspective or sectional partial view of the window or door frame area along the line VI-VI of FIG. 1st

Die in Fig. 1 gezeigte Schienenfahrzeugzelle besteht aus einzeln vorgefertigten Dach-, Boden-, Stirn- (nicht er­sichtlich) und Seitenwand-Zellmodulen 2.1 bis 2.4, die im zusammengefügten Zustand das aus einzelnen Tragprofil­teilen gitterartig zusammengesetzte Traggerüst der Fahr­zeugzelle und die die Schubversteifung übernehmende Sandwich-Beplankung des Traggerüstes ergeben.The rail vehicle cell shown in Fig. 1 consists of individually prefabricated roof, floor, end (not shown) and side wall cell modules 2.1 to 2.4, which, in the assembled state, the supporting structure of the vehicle cell, which is composed of individual supporting profile parts, and the sandwich which takes over the shear stiffening - Planking of the supporting structure results.

Der Aufbau und die Fertigung der Zellmodule wird anhand eines Seitenwand-Teilmoduls unter Bezug auf Fig. 2 er­läutert. Der Zellmodul ist als Sandwichstruktur mit inneren und äußeren Deckschichten 4, 6 aus Faserver­bundwerkstoff ausgebildet, zwischen die eine Wabenkern-­Stützschicht 8 und die zum Zellmodul gehörenden Tragprofilteile 10 des Traggerüstes als integraler Bestandteil der Sandwichstruktur eingeklebt werden. Die Tragprofilteile 10 sind gitterartig angeordnet, derart, daß die äußeren Quer- und Längsprofile 12, 14 eine in Umfangsrichtung geschlossene Randeinfassung für die Sandwichstruktur bilden.The construction and manufacture of the cell modules is explained using a side wall submodule with reference to FIG. 2. The cell module is designed as a sandwich structure with inner and outer cover layers 4, 6 made of fiber composite material, between which a honeycomb core support layer 8 and the supporting profile parts 10 of the supporting structure belonging to the cell module are glued as an integral part of the sandwich structure. The support profile parts 10 are arranged in a lattice-like manner such that the outer transverse and longitudinal profiles 12, 14 form a circumferential border for the sandwich structure.

Zur Herstellung des Seitenwand-Zellmoduls dient eine Formschale 16 aus Aluminium- oder Stahlblech, die mittels einer Abstützvorrichtung 18 in horizontalerA molded shell 16 made of aluminum or steel sheet is used to produce the side wall cell module

Lage aufgeständert ist und auf der zunächst die beiden Deckschichten 4, 6 jeweils einzeln mit einem vorwiegend ± 45°-Faserlagenaufbau hergestellt und ausgehärtet werden. Nach dem Aushärten besitzen die formschalenseiti­gen Außenflächen der Deckschichten 4, 6 eine sehr glatte Oberflächenstruktur, so daß auf eine aufwendige Ober­flächen-Nachbearbeitung oder eine nachträglich auf die Außenfläche der inneren Deckschicht 4 aufgebrachteLayer is raised and on which the two cover layers 4, 6 are first individually manufactured and cured with a predominantly ± 45 ° fiber layer structure. After hardening, the outer surfaces of the cover layers 4, 6 on the shell side have a very smooth surface structure, so that a complicated surface reworking or a subsequent application to the outer surface of the inner cover layer 4 is carried out

Fahrzeug-Innenverkleidung verzichtet werden kann. Die äußere, auf der Formschale 16 aufliegende Deckschicht 6 wird mit einer Klebeschicht, etwa einer Phenolharzlage oder einem Folienkleber (nicht gezeigt) belegt, worauf­hin die Tragprofilteile 10 aufgelegt und in die Zwischenräume zwischen diesen eventuell noch benötig­te Einlegeteile, z. B. Krafteinleitungselemente in Form von Glasschnitzelblöcken (ebenfalls nicht gezeigt) eingesetzt werden. Die verbleibenden Flächenbereiche ­mit Ausnahme der für die Fenster- und Türausschnitte freizuhaltenden Flächenfelder - werden nunmehr mit dem Wabenkernmaterial 8 belegt. Aus Gründen der Arbeitserspar­nis wird dieses nur grob zugeschnitten und die entstehen­den Lücken zu den Tragprofilteilen 10 werden mit einem Ausgleichsmaterial in Form eines Ausgleichsklebers oder -schaums ausgefüllt, woraufhin die innere Deck­schicht 4 ebenfalls wieder unter Zwischenlage eines Folienklebers oder einer Phenolharzlage aufgesetzt wird und sämtliche Komponenten unter Druck- und Wärmeeinwir­kung zum fertigen Zellmodul verklebt werden.Vehicle interior trim can be dispensed with. The outer cover layer 6 lying on the molded shell 16 is covered with an adhesive layer, for example a phenolic resin layer or a film adhesive (not shown), whereupon the support profile parts 10 are placed and inserted into the interspaces between them, any insert parts that may still be required, e.g. B. force introduction elements in the form of glass chips blocks (also not shown) can be used. The remaining surface areas, with the exception of the surface fields to be kept free for the window and door cutouts, are now covered with the honeycomb core material 8. For reasons of labor saving, this is only roughly cut and the resulting gaps to the supporting profile parts 10 are filled with a compensating material in the form of a compensating adhesive or foam, whereupon the inner cover layer 4 is again placed with the interposition of a film adhesive or a phenolic resin layer and all components underneath Pressure and heat effects are glued to the finished cell module.

Die Tragprofilteile 10 sind als Hohlkammerprofile aus Aluminium oder Faserverbundwerkstoff vorgefertigt und werden im Hinblick auf eine exakte Positionierung inner­halb des Zellmoduls bereits vor ihrer Einbeziehung in die Sandwichstruktur fest miteinander verbunden, und zwar vorzugsweise durch Spreiz-Dübelverbindungen 20 gemäß Fig. 3, die jeweils aus einem in das offene Ende des einen Tragprofilteils 10 eingesetzten Dübelteil 22 und mit diesem unter Aufspreizung des Dübelteils 22 verschraub­ten, über Durchgangsbohrungen in den Hohlkammerwänden des anderen Tragprofilteils 14 eingeführten Befestigungs­schrauben 24 bestehen.The support profile parts 10 are prefabricated as hollow chamber profiles made of aluminum or fiber composite material and, with regard to an exact positioning within the cell module, are already included in FIG the sandwich structure firmly connected to each other, preferably by expansion dowel connections 20 according to FIG. 3, each screwed from a dowel part 22 inserted into the open end of the one support profile part 10 and screwed to it with the dowel part 22 spreading, via through holes in the hollow chamber walls of the other support profile part 14 are inserted mounting screws 24.

Die Formschale 16 wird auch zur Herstellung von Zellmodu­len benutzt, die - wie die Dachmodule 2.1 - eine ein­seitig gekrümmte Querschnittskonfiguration aufweisen. Für diesen Zweck wird die Formschale 16, z. B. durch ent­sprechende Profilschablonen, in den gewünschten, elastisch verformten Zustand an der Abstützvorrichtung 18 fixiert, woraufhin der gekrümmte Zellmodul in gleicher Weise wie der oben beschriebene, ebene Zellmodul hergestellt wird, abgesehen davon, daß natürlich entsprechend vorgebogene Tragprofilteile 10 benötigt werden.The molded shell 16 is also used for the production of cell modules which, like the roof modules 2.1, have a cross-sectional configuration that is curved on one side. For this purpose, the molded shell 16, z. B. by appropriate profile templates, fixed in the desired, elastically deformed state on the support device 18, whereupon the curved cell module is produced in the same way as the above-described flat cell module, apart from the fact that accordingly pre-bent support profile parts 10 are required.

Zusammengefügt werden die einzelnen Zellmodule über pass­genaue Steckverbindungen, die sich großflächig über den gesamten Außenumfang der Zellmodule erstrecken. Zu die­sem Zweck sind die randseitigen Tragprofilteile 12 und 14 nur über einen Teil ihrer Profilbreite mit den Deck­schichten 4, 6 verklebt und werden über ihre deckschicht­freien Profilabschnitte mit dem randseitigen Tragprofil­teil 12 bzw. 14 des benachbarten Zellmoduls lastüber­tragend verkoppelt. In Fig. 4 ist eine derartige Pass-­Fügeverbindung zwischen Boden- und Seitenwandmodul 2.2 und 2.4 gezeigt. Die Doppelkammer-Tragprofilteile 14, die die äußere, unter Zwischenlage des Ausgleichsklebers oder -schaums 26 an den Wabenkern 8 angrenzende Rand­einfassung des Zellmoduls bilden, sind etwa nur über die Hälfte ihrer Profilbreite in die Sanwichstruktur einbe­ zogen und werden mit Hilfe eines Steckverbindungsprofils 28, das auf die deckschichtfreien Hohlkammer-Profilab­schnitte aufgeschoben und mit diesen flächig verklebt wird, fest miteinander verbunden, wobei die freien Pro­filschenkel des Verbindungsprofils 28 im zusammengefüg­ten Zustand bündig an den Deckschichten 4, 6 der Zellmo­dule 2.2 bzw. 2.4 anliegen.The individual cell modules are assembled using precisely fitting plug connections that extend over a large area over the entire outer circumference of the cell modules. For this purpose, the edge-side support profile parts 12 and 14 are glued to the cover layers 4, 6 only over part of their profile width and are coupled via their cover layer-free profile sections to the edge-side support profile part 12 and 14 of the adjacent cell module in a load-transmitting manner. 4 shows a pass-fit connection of this type between the base and side wall modules 2.2 and 2.4. The double-chamber support profile parts 14, which form the outer border of the cell module adjoining the honeycomb core 8 with the interposition of the compensating adhesive or foam 26, are approximately only half of their profile width in the Sanwich structure pulled and are firmly connected to each other with the help of a connector profile 28, which is pushed onto the cover layer-free hollow chamber profile sections and glued to them, the free profile legs of the connection profile 28 in the assembled state flush with the cover layers 4, 6 of the cell modules 2.2 or 2.4 concern.

Bei der in Fig. 5 gezeigten Pass-Fügeverbindung zwi­schen Dach- und Seitenwandmodul 2.1, 2.3 ist als randsei­tiges Tragprofilteil des Dachmoduls 2.1 ein einseitig offenes Hohlkammerprofil 30 vorgesehen, dessen freie Profilschenkel 32 beim Zusammenfügen der Zellmodule 2.1, 2.3 engsitzend auf das randseitige Gegenprofil 14 des Seitenwandmoduls 2.3 aufschiebbar sind, so daß die Randprofile 14, 30 wiederum unter exakter gegenseiti­ger Fixierung der zugehörigen Zellmodule 2.1 und 2.3 miteinander verklebt werden können.In the pass-fit connection shown in FIG. 5 between the roof and side wall modules 2.1, 2.3, a hollow profile 30 that is open on one side is provided as the edge-side supporting profile part of the roof module 2.1, the free profile legs 32 of which, when the cell modules 2.1, 2.3 are assembled, fit snugly onto the edge-side counter profile 14 of the Sidewall module 2.3 can be pushed on, so that the edge profiles 14, 30 can in turn be glued to one another with exact mutual fixation of the associated cell modules 2.1 and 2.3.

Die beschriebenen, aus in seitlicher Richtung passgenau zusammenschiebbaren und dann miteinander verklebten Rand­profilteilen 12, 14, 30 bestehenden Fügeverbindungen werden in analoger Weise auch zwischen den übrigen Zell­modulen,etwa zwischen den Dach- und Stirnwandmodulen oder zum Einfügen von Zwischenwandmodulen 2.4 (Fig. 1) verwendet. In Bereichen einer örtlichen Spannungskonzen­tration, für die die Festigkeit der Klebeverbindung nicht ausreicht, können die Traggerüstteile 10 mit den Deck­schichten 4, 6 oder - an den Passfügeverbindungen zwischen den Zellmodulen - untereinander zusätzlich noch vernietet oder verschraubt werden.The joint connections described, consisting of edge profile parts 12, 14, 30 which can be pushed together precisely in the lateral direction and then bonded to one another, are also used in an analogous manner between the other cell modules, for example between the roof and end wall modules or for inserting intermediate wall modules 2.4 (FIG. 1) . In areas of a local stress concentration for which the strength of the adhesive connection is not sufficient, the supporting structure parts 10 with the cover layers 4, 6 or - at the fitting connections between the cell modules - can also be riveted or screwed to one another.

Fig. 5 zeigt ferner die Möglichkeit, den Zellmodul mit einer gegenüber der Profilhöhe der randseitigen Tragpro­filteile unterschiedlichen Wanddicke auszubilden, derart, daß durch Einfügen entsprechender Wabenkernstreifen 8.2 bei der Zellmodulfertigung ein allmählicher Über­gang von der Sandwichdicke zur Profilhöhe des rand­seitigen Tragprofilteils 14 erreicht wird.Fig. 5 also shows the possibility of forming the cell module with a different wall thickness compared to the profile height of the edge-side support profile parts, such that by inserting appropriate honeycomb core strips 8.2 in cell module production a gradual transition from the sandwich thickness to the profile height of the edge-side support profile part 14 is achieved.

In gleicher Weise wie die Tragprofilteile 10 werden auch die Fenster- und Türrahmenprofile 34 und 36 in die Sandwichstruktur 2 mitintegriert, wie die Fig. 6a, b zeigt. Dabei sind Sichtradien an den Ecken der Fenster- bzw. Türausschnitte bereits an den Rahmenprofilen 34, 36 ausgebildet, und überschüssiges Deckschichtmaterial wird nach dem Verkleben der Sandwichstruktur 2 durch Besäumen längs der Rahmenprofilkanten maßgenau entfernt. Die Fensterscheiben 38 werden zusammen mit einer Gummi­dichtung 40 und einer Randeinfassung 42 nachträglich an den Rahmenprofilen 34 befestigt. Das Türrahmenprofil 36 enthält einen einstückig angeformten, den Türanschlag bildenden Profilabschnitt 44 (Fig. 6b); wahlweise kann das Türrahmenprofil 36 jedoch auch - längs der in Fig. 6b gestrichelten Trennungslinie - zweiteilig ausgebil­det sein und der Profilabschnitt 44 erst nach Fertig­stellung des Seitenwandmoduls 2.3 am Türrahmenprofil 36 befestigt werden.In the same way as the support profile parts 10, the window and door frame profiles 34 and 36 are also integrated into the sandwich structure 2, as shown in FIGS. 6a, b. Visible radii at the corners of the window or door cutouts are already formed on the frame profiles 34, 36, and excess cover layer material is removed after trimming the sandwich structure 2 by trimming along the frame profile edges. The window panes 38 are subsequently attached to the frame profiles 34 together with a rubber seal 40 and a rim 42. The door frame profile 36 contains an integrally molded profile section 44 forming the door stop (FIG. 6b); Alternatively, however, the door frame profile 36 can also be formed in two parts - along the dividing line dashed in FIG. 6b - and the profile section 44 can be fastened to the door frame profile 36 only after the side wall module 2.3 has been completed.

Gemäß einer Fertigungsvariante für die Zellmodule wird auf eine vorherige Aushärtung der Deckschichten 4, 6 verzichtet, und statt dessen werden diese im noch unge­härteten Zustand zusammen mit den Wabenkern- und Trag­gerüstteilen 8, 10 auf das Formwerkzeug 16, 18 aufge­legt und dann unter gleichzeitiger Verklebung der Sandwichstruktur ausgehärtet. In diesem Fall empfiehlt es sich allerdings, die Außenfläche zumindest einer, vorzugsweise der inneren Deckschicht 4 mit einer vorgehärteten, beim Aushärten des Deckschichtmaterials integral mit diesem verklebten Außenhaut zu belegen.According to a production variant for the cell modules, the outer layers 4, 6 are not cured beforehand, and instead they are placed in the still uncured state together with the honeycomb core and supporting frame parts 8, 10 on the molding tool 16, 18 and then with simultaneous bonding of the Hardened sandwich structure. In this case, however, it is advisable to cover the outer surface of at least one, preferably the inner cover layer 4 with a pre-hardened outer skin that is integrally bonded to it when the cover layer material hardens.

Claims (13)

1. Fahrzeugzelle, insbesondere für ein Schienenfahrzeug, bestehend aus einem Traggerüst und an diesem befestig­ten Sandwichteilen, die jeweils eine äußere und eine innere Deckschicht und eine zwischen diese einge­klebte Stützschicht enthalten,
dadurch gekennzeichnet, daß
die Fahrzeugzelle aus einzeln fertiggestellten Zell­modulen (2) aufgebaut ist, die jeweils in Integralbau­weise als Sandwichstruktur mit im Bereich der Stütz­schicht (8) eingefügten, an den Deckschichten (4, 6) befestigten Traggerüstteilen (10, 12, 14, 30) ausge­bildet und randseitig an den Traggerüstteilen mit Passverbindungen (28, 32) zum Zusammenfügen der Zellmodule versehen sind.1. Vehicle cell, in particular for a rail vehicle, consisting of a supporting frame and sandwich parts attached to it, each of which contains an outer and an inner cover layer and a support layer glued between them,
characterized in that
The vehicle cell is constructed from individually finished cell modules (2), each of which is constructed in an integral construction as a sandwich structure with supporting frame parts (10, 12, 14, 30) inserted in the area of the supporting layer (8) and fastened to the cover layers (4, 6) are provided on the supporting frame parts with fitting connections (28, 32) for joining the cell modules. 2. Fahrzeugzelle nach Anspruch 1,
dadurch gekennzeichnet, daß
die Passverbindungen(28, 32) aus lastübertragend mit­einander verkoppelten Steckverbindungselementenbe­stehen.2. Vehicle cell according to claim 1,
characterized in that
the mating connections (28, 32) consist of plug-in connection elements which are coupled to each other for load transfer. 3. Fahrzeugzelle nach Anspruch 1 oder 2,
dadurch gekennzeichnet, daß
die Pass- bzw. Steckverbindungselemente (28, 32) miteinander verklebt sind.3. Vehicle cell according to claim 1 or 2,
characterized in that
the fitting or connector elements (28, 32) are glued together. 4. Fahrzeugzelle nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß die einzelnen Zellmodule (2) randseitig jeweils vollständig von mit den Passverbindungen versehenen Traggerüstteilen (12, 14) umschlossen sind.4. Vehicle cell according to one of the preceding claims, characterized in that the individual cell modules (2) on the edges are each completely surrounded by supporting frame parts (12, 14) provided with the fitting connections. 5. Fahrzeugzelle nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß die randseitigen Traggerüstteile (12, 14) als pass­genau ineinander schiebbare Hohlprofilteile ausge­bildet sind.5. Vehicle cell according to one of the preceding claims, characterized in that the edge-side supporting frame parts (12, 14) are formed as hollow profile parts which can be pushed into one another with precise fit. 6. Fahrzeugzelle nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß die Traggerüstteile (10) innerhalb der einzelnen Zellmodule (2) gitterartig miteinander verbunden sind.6. Vehicle cell according to one of the preceding claims, characterized in that the supporting structure parts (10) within the individual cell modules (2) are interconnected in a grid-like manner. 7. Fahrzeugzelle nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß die Traggerüstteile (10) innerhalb der einzelnen Zellmodule (2) miteinander verschraubt sind.7. Vehicle cell according to one of the preceding claims, characterized in that the supporting frame parts (10) are screwed together within the individual cell modules (2). 8. Fahrzeugzelle nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß als Stützschicht (8) für die Zellmodule (2) jeweils über ein Ausgleichsmaterial (26) an die Gerüstteile (10) angefügte Wabenkern- oder Schaumstoff-Zuschnitte vorgesehen sind.8. Vehicle cell according to one of the preceding claims, characterized in that as a support layer (8) for the cell modules (2) each via a compensating material (26) to the frame parts (10) attached honeycomb core or foam cuts are provided. 9. Fahrzeugzelle nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß die Rahmenprofile (34, 36) für die Fahrzeugfenster und -türen in gleicher Weise wie die Traggerüstteile (10) in die jeweiligen Zellmodule (2) mitintegriert sind.9. Vehicle cell according to one of the preceding claims, characterized in that the frame profiles (34, 36) for the vehicle windows and doors in the same way as the supporting structure parts (10) in the respective cell modules (2) are also integrated. 10. Fahrzeugzelle nach Anspruch 9, dadurch gekennzeichnet, daß die Deckschichten (4, 6) nach Fertigstellung des je­weiligen Zellmoduls (2) längs der Fenster- bzw. Türrahmenprofile (34, 36) besäumt sind.10. Vehicle cell according to claim 9, characterized in that the cover layers (4, 6) are trimmed along the window or door frame profiles (34, 36) after completion of the respective cell module (2). 11. Fahrzeugzelle nach einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, daß die Deckschichten (4, 6) aus mit den Traggerüstteilen (10) flächig verklebten Faserverbundschichten beste­hen.11. Vehicle cell according to one of the preceding claims, characterized in that the cover layers (4, 6) consist of surface-bonded fiber composite layers with the supporting frame parts (10). 12. Fahrzeugzelle nach Anspruch 11, dadurch gekennzeichnet, daß die Deckschichten (4, 6) mit den Traggerüstteilen (10) zusätzlich zu der Verklebung örtlich vernietet sind.12. Vehicle cell according to claim 11, characterized in that the cover layers (4, 6) with the supporting structure parts (10) are locally riveted in addition to the adhesive. 13. Fahrzeugzelle nach Anspruch 11 oder 12, dadurch gekennzeichnet, daß zumindest die Außenhaut einer Deckschicht (4, 6) durch ein getrennt vorgehärtetes Faserverbundlaminat ge­bildet ist.13. Vehicle cell according to claim 11 or 12, characterized in that at least the outer skin of a cover layer (4, 6) is formed by a separately pre-hardened fiber composite laminate.
EP89117089A 1988-11-15 1989-09-15 Vehicle body Expired - Lifetime EP0369134B1 (en)

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DE3838686A DE3838686C2 (en) 1988-11-15 1988-11-15 Vehicle compartment
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Also Published As

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ES2041383T3 (en) 1993-11-16
EP0369134B1 (en) 1993-06-16
KR900007673A (en) 1990-06-01
DE3838686A1 (en) 1990-05-17
JPH02193760A (en) 1990-07-31
ATE90631T1 (en) 1993-07-15
US5042395A (en) 1991-08-27
DE3838686C2 (en) 1993-10-21
DE58904721D1 (en) 1993-07-22
JPH0639254B2 (en) 1994-05-25

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